US20120124874A1 - Lighting mount for interior-lighted signage and method of retrofitting a lighted sign - Google Patents
Lighting mount for interior-lighted signage and method of retrofitting a lighted sign Download PDFInfo
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- US20120124874A1 US20120124874A1 US13/302,235 US201113302235A US2012124874A1 US 20120124874 A1 US20120124874 A1 US 20120124874A1 US 201113302235 A US201113302235 A US 201113302235A US 2012124874 A1 US2012124874 A1 US 2012124874A1
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- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
- G09F13/00—Illuminated signs; Luminous advertising
- G09F13/04—Signs, boards or panels, illuminated from behind the insignia
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49716—Converting
Definitions
- the present invention relates to lighted signs and, more particularly, to electric lighting fixtures for internally-lit or back-lit signs.
- Internally-lighted or back-lit signs typically have a housing with one or more electric lighting fixtures for supporting and energizing gas-discharge electric lamps' (such as neon or fluorescent tube lamps), and associated electrical wiring to conduct electricity from the lighting fixtures to a power source.
- At least one side of the housing supports a display sheet (such as a rigid, semi-rigid, or flexible sheet made of cloth, paper, glass, polymer, or the like) that is at least partially translucent, the sheet including lettering, symbols, artwork, or the like. Light from the lamps inside the housing projects through the display sheet to illuminate the lettering or artwork on the sheet, for example.
- the present invention provides a lighting mount that facilitates the retrofitting of existing interior-lit signs, which were originally manufactured for supporting and energizing gas-discharge lamps such as high-output fluorescent or neon tube lamps, with alternative lamps such as low-voltage LED lamps or the like.
- the lighting mount of the present invention can be used in the production of new interior-lit signs that are equipped for low-voltage lighting, substantially without modifying the mechanical or structural features of the signs, which may have originally been designed to be internally lit by one or more higher-voltage fluorescent or neon tube lamps or the like.
- a lamp support assembly for interior lighting of a sign.
- the lamp support assembly includes an elongate support member and a pair of end caps.
- the elongate support member is capable of supporting a plurality of electric lamp units, such as LED lamp units, between opposite end portions of the elongate support member.
- the end caps are attached to the elongate support member at opposite end portions thereof Each of the end caps has an inwardly-facing side for engaging the respective opposite end portions of the elongate support member, and has an outwardly-facing side with a mechanical coupling element.
- the mechanical coupling element is configured to engage a standard mount such as a mount designed for supporting a gas-discharge lamp such as a fluorescent or neo tube lamp or the like.
- the elongate support member and the end caps are releasably supportable by and between a corresponding pair of the standard mounts when the standard mounts are supported in spaced arrangement on respective frame portions of the sign.
- a method for retrofitting an internally-lighted sign that is fitted with one or more gas-discharge lamps or the like.
- the method includes the steps of: (i) removing the gas-discharge tube lamps from between corresponding pairs of electro-mechanical couplings that are positioned along an interior of the sign; (ii) cutting an elongate support member to fit between the respective pair or pairs of electro-mechanical couplings; (iii) positioning respective end caps at opposite end portions of the elongate support member; (iv) positioning one or more electric lamp units along the elongate support member; and (v) positioning the end caps, elongate support member, and electric lamp units between the pair of electro-mechanical couplings.
- the electric lamp units may be low-voltage lamp units, so that low-voltage wiring can be electrically connected to the lamp units and routed along the elongate support member to a low-voltage power source in electrical communication with the sign.
- low-voltage wiring can be electrically connected to the lamp units and routed along the elongate support member to a low-voltage power source in electrical communication with the sign.
- high voltage wiring, power sources, ballast, or the like, which had been associated with the gas-discharge tube lamps can be removed and/or disabled.
- the electro-mechanical couplings can be replaced with purely mechanical couplings that are structurally similar or identical to the electro-mechanical couplings being replaced.
- the present invention provides a lighting mount and method that facilitates the replacement of gas-discharge tube lamps in internally-lit signs with low-voltage lamps, such as LED lamps or the like.
- the lighting mount can be fitted between pairs of standard or conventional electro-mechanical couplings, such as couplings that were originally designed to support and energize gas-discharge tube lamps.
- the lighting mount need not be electrically coupled to the electrical conductors of the electro-mechanical couplings, but instead could be only mechanically coupled, so that the electrical wiring, ballast, or other electrical components could be disabled and/or removed from the sign.
- high voltage and/or high power consumption lamps can be readily replaced with low voltage and/or low power consumption lamps in an existing internally-lit sign originally equipped or designed for gas-discharge lamps such as fluorescent or neon tube lamps, or in a newly-constructed internally lit sign that was originally designed for gas-discharge tube lamps, substantially without need for modifying the structure of the sign.
- the retrofitted or newly-constructed sign can thus be operated with lower energy and maintenance costs.
- FIG. 1 is perspective view of a lighted sign assembly including a lamp support assembly in accordance with the present invention, and showing removal of a gas-discharge tube lamp;
- FIG. 2 is an end elevation of the lighted sign assembly of FIG. 1 , and with the display sheet removed;
- FIG. 4 is a perspective view of a lamp support assembly that is part of the lighted sign assembly of FIG. 1 ;
- FIG. 5 is an end elevation of an elongate support member that is part of the lamp support assembly of FIG. 4 ;
- FIG. 6 is a perspective view of the elongate support member of FIG. 6 ;
- FIG. 7 is a perspective view of another lamp support assembly
- FIG. 8 is an end elevation of an elongate support member that is part of the lamp support assembly of FIG. 7 ;
- FIG. 9 is a perspective view of the elongate support member of FIG. 7 ;
- FIG. 11 is a perspective view of an outboard side of the end cap of FIG. 10 ;
- FIG. 12 is a plan view of the inboard side of the end cap of FIG. 10 ;
- FIG. 13 is a plan view of the outboard side of the end cap of FIG. 10 ;
- FIG. 14 is a front elevation of the end cap of FIG. 10 ;
- FIG. 15 is a sectional view of the end cap, taken along section line XV-XV of FIG. 14 ;
- FIG. 16 is a sectional view of the end cap, taken along section line XVI-XVI of FIG. 14 ;
- FIG. 17 is an end elevation of the end cap of FIG. 10 ;
- FIG. 18 is a sectional view of the end cap, taken along section line XVIII-XVIII of FIG. 17 ;
- FIG. 19 is a perspective view of the inboard side of another end cap, which is compatible for use with the lamp support assemblies of FIGS. 4 and 7 ;
- FIG. 20 is a plan view of the outboard side of the end cap of FIG. 19 ;
- FIGS. 21A and 21B are perspective views of the inboard side of the end cap of FIG. 19 , with FIG. 21A showing cross sections of the elongate support members of FIGS. 5 and 8 superimposed in phantom;
- FIG. 22 is a perspective view of a pair of conventional socket mounts for supporting and energizing a gas-discharge tube lamp
- FIG. 23 is a perspective view of another pair of conventional socket mounts for supporting and energizing a gas-discharge tube lamp.
- FIG. 24 is a plan view of a retrofit kit for use in converting a sign over from gas-discharge tube lamps to low-voltage lamp units.
- a lamp support assembly 10 is provided for interior lighting of a sign 12 ( FIG. 1 ), which may be a single or double-sided sign (or a sign having substantially any number of sides or surfaces) that is internally-lit or “back-lit”.
- Lamp support assembly 10 allows for sign 12 , which may have been originally designed and manufactured for internal lighting by one or more gas-discharge lamps such as fluorescent or neon tube lamps 21 or the like, to be retrofitted with alternative lighting, such as low-voltage lighting, largely or substantially without modifications to the original sign.
- Lamp support assembly 10 includes an elongate support member 14 for supporting one or more electric lamp units 28 which, in the illustrated embodiment, each include four light emitting diode (LED) lamps 32 ( FIGS. 1 and 3 ).
- Elongate support member 14 has opposite end portions 14 a, 14 b, and is sized to be positioned between generally parallel frame members 22 of sign 12 .
- Each opposite end portion 14 a, 14 b of elongate support member 14 is fitted with an end cap 16 .
- Each end cap 16 has an inwardly-facing side 16 a and an outwardly-facing side 16 b, such as shown in FIGS. 10-13 .
- Inwardly-facing sides 16 a are configured to engage one of the opposite end portions 14 a, 14 b of the elongate support member 14
- outwardly-facing sides 16 b include a mechanical coupling element 18 for engaging one of two standard electro-mechanical mounts or sockets 20 a, 20 b that are configured for supporting and energizing fluorescent tube lamp 21 , as will be described below.
- purely-mechanical mounts or sockets 40 a, 40 b that are structurally similar or identical to standard mounts or sockets 20 a, 20 b, respectively, but which lack electrical conductors, may be provided in place of standard mounts or sockets 20 a, 20 b.
- lamp support assembly 10 is releasably supportable by and between the mounts 20 a, 20 b or 40 a, 40 b via releasable engagement of mechanical coupling elements 18 ( FIGS. 4 , 7 , 10 , 11 , 13 - 15 , 17 , and 18 ), which are provided on the mounts 20 a, 20 b and 40 a, 40 b.
- Sign 12 further includes a display sheet 23 that may be a rigid, semi-rigid, or flexible sheet material, which is supported by frame members 22 or by coupling elements (e.g. clips or other mechanical fasteners) or adhesives or the like, that are associated with the sign.
- display sheet 23 is at least partially translucent so that at least some of the light emitted from inside of the sign 12 can pass through the sheet 23 and can be seen by persons located within view of the sign.
- the translucent portions of the display sheet 23 may be openings or apertures in the sheet.
- the display sheet may have substantially any lettering, symbols, artwork, coloring, indicia, or the like, which are made visible (or made more visible) when illuminated from behind (i.e., from inside of sign 12 ).
- Elongate support member 14 has an I-beam cross section with a double web portion 24 and flange portions 26 on opposite ends of the web portion 24 ( FIGS. 1-4 , 6 , and 7 ).
- Web portion 24 comprises a pair of spaced plates 24 a, 24 b that are joined together by the flange portions 26 , such as shown in FIGS. 5 and 6 .
- Elongate support member 14 is configured to support the plurality of electric lamp units 28 along one or both opposite sides of web portion 24 ( FIGS. 1-3 ), such as for lighting a one-sided sign or a two-sided sign, respectively.
- an alternative support member 14 ′ includes a web portion 24 ′ that is comprised of a single plate with opposite flange portions 26 ′.
- Flange portions 26 ′ include L-shaped flange tips 27 ′ that may enhance the structural rigidity of support member 14 ′, and that may provide a retaining function for electric lamp units that are positioned along the web portion 24 ′, particularly if the L-shaped flange tips 27 ′ along one side of web portion 24 ′ are spaced more closely together than the width of electric lamp units 28 so that the lamp units can generally only be slid longitudinally along support member 14 until fixed in place, such as described below.
- Elongate support members 14 , 14 ′ may be extruded from metal or non-metal material, for example, such as aluminum or plastic, which may be readily cut using a saw or other cutting tool to obtain a finished length as desired.
- the inwardly-facing sides 16 a of end caps 16 include a plurality of wall-like projections 30 ( FIGS. 1-4 , 7 , 10 - 12 , 14 , 15 , 17 , and 18 ) for engaging the I-beam cross section of the elongate support member 14 at the opposite ends 14 a, 14 b thereof, such as shown in FIGS. 1-4 .
- Projections 30 include a pair of flange-engaging walls 30 a on respective opposite ends of end cap 16 , and a pair of web-engaging walls 30 b that span substantially across inwardly-facing side 16 a of end cap 16 , between flange-engaging walls 30 a.
- a flange-receiving gap 31 a FIGS.
- each flange-engaging wall 30 a is defined between each flange-engaging wall 30 a and the nearby ends of web-engaging walls 30 b for receiving the respective flange portions 26 or 26 ′ of elongate support members 14 or 14 ′.
- a web-receiving gap 3 lb ( FIGS. 10 and 12 ) is defined between the pair of web-engaging walls 30 b, for receiving the single-wall web portion 24 ′ of support member 14 ′.
- Web-engaging walls 30 b are spaced such that their outwardly-facing surfaces (i.e., opposite the gap 31 b ) can frictionally engage the inner surfaces of the spaced plates 24 a, 24 b that form dual-wall web portion 24 of elongate support member 14 .
- projections 30 are arranged to frictionally engage respective web and flange portions of either support member 14 , 14 ′, so that end caps 16 are at least frictionally retained at the opposite ends 14 a, 14 b of the elongate support member 14 , 14 ′.
- Mechanical coupling element 18 which is disposed along outwardly-facing side 16 b of end cap 16 ( FIGS. 4 , 7 , 10 , 11 , 13 - 15 , 17 , and 18 ), substantially replicates the structure of the conventional electro-mechanical end coupler 21 a of a “high output” fluorescent tube lamp 21 , and is shaped to engage or be received in the conventional or standard electro-mechanical sockets or mounts 20 a, 20 b.
- Standard electro-mechanical sockets or mounts 20 a, 20 b may be of the type commonly referred to as a “Kulka socket”, such as that shown and described in U.S. Pat. No. 5,122,074, the disclosure of which is hereby incorporated herein by reference, and such as may be available as Part Nos. 582GDF and/or 583GDF from Voltarc Technologies, Inc. of Waterbury, Conn.
- Mechanical coupling elements 18 include a base plate or flange 18 a and a male prong or projection 18 b extending outwardly from base plate 18 a ( FIGS. 4 , 7 , 10 , 11 , 13 - 15 , 17 , and 18 ).
- Male projection 18 b has a pair of opposite side walls 44 that are spaced from each other and joined at their ends by rounded end walls 46 to define an interior cavity 48 ( FIGS. 11 and 13 ).
- Inside of cavity 48 is a pair of recessed shoulders 50 that project outwardly from base plate 18 a, but not as far as do side walls 44 , and which form the outward extent of rounded end walls 46 so that a gap 52 is formed between end portions of the opposite side walls 44 ( FIGS.
- low-voltage wiring for lamp units 28 could be electrically coupled to electrical conductors mounted in the coupling elements 18 of the end caps 16 (i.e., to make coupling elements 18 substantially similar to the end couplers 21 a of fluorescent tube lamps 21 ).
- each lamp support assembly 10 to be installed in the sign's original electro-mechanical mounts or sockets 20 a, 20 b along the respective frame members 22 and electrically coupled to a power source in substantially the same manner as the fluorescent tube lamps 21 , as long as the power supplied to electro-mechanical mounts 20 a, 20 b is adjusted as appropriate for lamp units 28 (such as by cutting off the high voltage wiring 60 from ballast 34 and high-voltage power source 62 , and instead supplying low voltage power to wiring 60 with low-voltage power source 36 .
- an alternative end cap 116 has an inwardly-facing side 116 a ( FIGS. 19 , 21 A, and 21 B) including a plurality of wall-like projections 130 a, 130 b for engaging the I-beam cross section of either of the elongate support members 14 , 14 ′, such as shown in FIG. 21A .
- An outwardly-facing side 116 b of end cap 116 includes a mechanical coupling element 118 ( FIG. 20 ) that is substantially identical to coupling element 18 of end cap 16 , as described above.
- Wall-like projections 130 a, 130 b define flange-receiving gaps 131 a and web-receiving gaps 131 b ( FIGS. 19 and 21B ), which are substantially similar to gaps 31 a, 31 b between walls 30 a, 30 b of end cap 16 , as described above.
- web-engaging walls 130 b are discontinuous or segmented to define a pattern of gaps 131 c along their respective lengths.
- Gaps 131 c permit inwardly-facing side 116 b of end cap 116 to receive the dual-web elongate support member 14 in either of two orientations, such as shown in FIG. 21A , and/or to engage a dual-web elongate support member having shorter-length webs in which the flange portions would be received in gaps 131 c that are spaced inwardly from flange-engaging walls 130 a and flange-receiving gap 131 a, while also remaining capable of receiving a single-web elongate support member such as support member 14 ′, as shown.
- alternative end cap 116 can be mounted to different elongate support members in different orientations, which may facilitate directing light from lamp units 28 laterally toward the perimeter ends or sides of the sign, rather than directly outwardly through the display sheet 23 , for example.
- electro-mechanical mount 20 a is a fixed-position mount (such as Part No. 582GDF, available from Voltarc Technologies, Inc.) while electro-mechanical mount 20 b is a spring-loaded mount (such as Part No. 583GDF, available from Voltarc Technologies, Inc.), such as shown in FIGS. 1-3 and 22 .
- Mounts 20 a, 20 b include engaging portions or socket portions 54 for receiving conventional end couplers 21 a of fluorescent tube lamps 21 ( FIGS. 1-3 ), and respective mounting portions 56 a, 56 b ( FIGS. 2 and 22 ) for engaging a frame portion, such as frame member 22 .
- Mounting portion 56 b of spring-loaded mount 20 b includes a coil spring 58 ( FIGS.
- the purely-mechanical mounts or sockets 40 a, 40 b are structurally the same or substantially similar to standard mounts 20 a, 20 b including a fixed mechanical mount 40 a and a spring-loaded mechanical mount 40 b, and may be provided as optional replacements for electro-mechanical mounts 20 a, 20 b.
- Standard stand-off mount 20 ′ (or a corresponding purely-mechanical mount, not shown) may be used ( FIG. 23 ), which stands off from a mounting surface such as a frame member for supporting a fluorescent tube lamp (or lamp support assembly 10 ) substantially parallel to the mounting surface.
- Standard stand-off mounts 20 ′ include a fixed-position stand-off mount 20 a ′ (such as Part No. 530.2K, available from Voltarc Technologies, Inc.) and a spring-loaded stand-off mount 20 b ′ (such as Part No. 530.1K, available from Voltarc Technologies, Inc.).
- stand-off mounts 20 a ′, 20 b ′ each include a socket portion 54 ′ and a mounting portion or housing 56 ′, with an internal spring (not shown) disposed in the housing of spring-loaded stand-off mount 20 b ′ to bias its socket portion 54 ′ outwardly, such as shown in FIG. 23 .
- retrofit kit 42 includes one or more elongate extrusions 114 and a pair of end caps 16 for each elongate support member 14 that will be formed from elongate extrusions 114 .
- elongate extrusion is used for convenience, and that elongate support members 14 may be formed via any desired method, such as molding or machining or extruding or the like.
- retrofit kit 42 may include one or more mechanical replacement mounts or sockets 40 a, 40 b that can be used to replace conventional or standard sockets, and the kit 42 may also include one or more electric lamp units 28 , low-voltage wiring 38 , a low-voltage power source or converter 36 , mechanical fasteners 61 , adhesives 63 (such as double-sided adhesive pads 63 a or a chemical adhesive 63 b ), and/or the like.
- lamp support assembly 10 can be positioned between standard electro-mechanical mounts 20 a, 20 b, or between purely-mechanical mounts or sockets 40 a, 40 b, by first engaging the mechanical coupling element 18 of the end cap 16 at end 14 b of elongate support member 14 with the spring-loaded socket 20 b or 40 b, compressing the spring 58 to push mounting portion 56 (or a corresponding mounting portion of mechanical socket 40 b ) further into frame member 22 , and then aligning the other mechanical coupling element 18 of the end cap at the opposite end 14 a of elongate support member 14 with the fixed socket 20 a or 40 a, and releasing the assembly 10 so that spring 58 forces the mechanical coupling element 18 at the opposite end 14 a of elongate support member 14 into engagement with the fixed socket 20 a or 40 a, thereby retaining lamp support assembly 10 between the respective sockets 20 a or 40 a, and 20 b or 40 b.
- Low-voltage wiring 38 may be electrically coupled to low-voltage
- Lamp support assembly 10 may be fabricated by cutting elongate support member 14 , 14 ′ to a desired length, fitting end caps 16 to the opposite ends 14 a, 14 b of elongate support member 14 , 14 ′, and installing electric lamp units 28 along one or both sides of web portion 24 , 24 ′ of elongate support member 14 , 14 ′.
- Electrical lamp units 28 are typically installed along one or both sides of web portion 24 , 24 ′ of elongate support member 14 , 14 ′ using mechanical fasteners 61 ( FIGS.
- lamp units 28 prior to installation of the lamp support assembly 10 at the sign 12 , although lamp units 28 can be added later, if desired.
- the lamp units 28 may be inserted between L-shaped flange tips 27 ′ and web portion 24 ′ from either end of the elongate support member 14 ′, such as in stacked or spaced arrangement, and held in place by L-shaped flange tips 27 ′ and/or mechanical fasteners 61 , adhesives, or the like.
- Low-voltage wiring 38 may be pre-installed at lamp units 28 , or may be installed at lamp units 28 after they are attached to elongate support member 14 , 14 ′, and routed along elongate support member 14 , 14 ′.
- fluorescent tube lamps 21 can be removed from sign 12 ( FIG. 1 ) following the removal steps described above for lamp support assembly 10 (i.e. following the installation steps in reverse order), and lamp support assemblies 10 can then be installed between respective pairs of standard electro-mechanical mounting sockets 20 a, 20 b as described above.
- standard electro-mechanical mounting sockets 20 a, 20 b can be replaced with purely mechanical replacement sockets 40 a, 40 b once fluorescent tube lamps 21 are removed.
- the installer may choose whether to use standard electro-mechanical mounting sockets 20 a, 20 b or purely mechanical mounting sockets 40 a, 40 b at frame members 22 .
- the low-voltage electrical wiring 38 is routed to a low-voltage electrical power source 36 ( FIG. 1 ) so that the electric lamp units 28 can be supplied with the appropriate electrical power.
- the installer may choose to cut, remove, or disable any high-voltage wiring 60 ( FIG. 1 ) associated with the tube lamps 21 and ballast 34 and high-voltage power source 62 .
- the installer may also choose to remove or disable the ballast 34 , and may electrically couple low-voltage power source 36 to high voltage power source 62 via high-voltage wiring 64 , which may be routed in an approved method, either externally to sign 12 or through frame members 22 (which may be hollow extruded sections, as shown in FIGS. 1 and 2 ). Depending on local or national electrical codes, it may be permissible to route low-voltage wiring 38 outside of conduits or frame members, which can simplify the installation process.
- the present invention provides a lighting mount assembly and method that facilitates the retrofitting of existing interior-lit signs, which may have been originally manufactured for supporting and energizing high-output gas-discharge lamps, such as fluorescent or neon tube lamps or the like.
- the signs may be retrofitted with alternative lamps such as low-voltage LED lamps or the like, although it will be appreciated that principles of the present invention can be practiced in connection with substantially any type of lighting as an alternative to gas-discharge lamps such as fluorescent tube lamps.
- the lighting mount assembly can also be used in the production of new interior-lit signs that are equipped for low-voltage lighting, substantially without modifying the mechanical or structural features of the signs, which may have originally been designed to be internally lit by one or more fluorescent tube lamps or the like.
Abstract
Description
- The present application claims the priority benefit of U.S. provisional application Ser. No. 61/417,156, filed Nov. 24, 2010, which is hereby incorporated herein by reference in its entirety.
- The present invention relates to lighted signs and, more particularly, to electric lighting fixtures for internally-lit or back-lit signs.
- Internally-lighted or back-lit signs typically have a housing with one or more electric lighting fixtures for supporting and energizing gas-discharge electric lamps' (such as neon or fluorescent tube lamps), and associated electrical wiring to conduct electricity from the lighting fixtures to a power source. At least one side of the housing supports a display sheet (such as a rigid, semi-rigid, or flexible sheet made of cloth, paper, glass, polymer, or the like) that is at least partially translucent, the sheet including lettering, symbols, artwork, or the like. Light from the lamps inside the housing projects through the display sheet to illuminate the lettering or artwork on the sheet, for example.
- The present invention provides a lighting mount that facilitates the retrofitting of existing interior-lit signs, which were originally manufactured for supporting and energizing gas-discharge lamps such as high-output fluorescent or neon tube lamps, with alternative lamps such as low-voltage LED lamps or the like. Optionally, the lighting mount of the present invention can be used in the production of new interior-lit signs that are equipped for low-voltage lighting, substantially without modifying the mechanical or structural features of the signs, which may have originally been designed to be internally lit by one or more higher-voltage fluorescent or neon tube lamps or the like.
- In one form of the present invention, a lamp support assembly is provided for interior lighting of a sign. The lamp support assembly includes an elongate support member and a pair of end caps. The elongate support member is capable of supporting a plurality of electric lamp units, such as LED lamp units, between opposite end portions of the elongate support member. The end caps are attached to the elongate support member at opposite end portions thereof Each of the end caps has an inwardly-facing side for engaging the respective opposite end portions of the elongate support member, and has an outwardly-facing side with a mechanical coupling element. The mechanical coupling element is configured to engage a standard mount such as a mount designed for supporting a gas-discharge lamp such as a fluorescent or neo tube lamp or the like. The elongate support member and the end caps are releasably supportable by and between a corresponding pair of the standard mounts when the standard mounts are supported in spaced arrangement on respective frame portions of the sign.
- In another form of the present invention, a method is provided for retrofitting an internally-lighted sign that is fitted with one or more gas-discharge lamps or the like. The method includes the steps of: (i) removing the gas-discharge tube lamps from between corresponding pairs of electro-mechanical couplings that are positioned along an interior of the sign; (ii) cutting an elongate support member to fit between the respective pair or pairs of electro-mechanical couplings; (iii) positioning respective end caps at opposite end portions of the elongate support member; (iv) positioning one or more electric lamp units along the elongate support member; and (v) positioning the end caps, elongate support member, and electric lamp units between the pair of electro-mechanical couplings. The electric lamp units may be low-voltage lamp units, so that low-voltage wiring can be electrically connected to the lamp units and routed along the elongate support member to a low-voltage power source in electrical communication with the sign. Optionally, high voltage wiring, power sources, ballast, or the like, which had been associated with the gas-discharge tube lamps, can be removed and/or disabled. Optionally, the electro-mechanical couplings can be replaced with purely mechanical couplings that are structurally similar or identical to the electro-mechanical couplings being replaced.
- Therefore, the present invention provides a lighting mount and method that facilitates the replacement of gas-discharge tube lamps in internally-lit signs with low-voltage lamps, such as LED lamps or the like. The lighting mount can be fitted between pairs of standard or conventional electro-mechanical couplings, such as couplings that were originally designed to support and energize gas-discharge tube lamps. In a typical retrofit installation, the lighting mount need not be electrically coupled to the electrical conductors of the electro-mechanical couplings, but instead could be only mechanically coupled, so that the electrical wiring, ballast, or other electrical components could be disabled and/or removed from the sign. Thus, high voltage and/or high power consumption lamps can be readily replaced with low voltage and/or low power consumption lamps in an existing internally-lit sign originally equipped or designed for gas-discharge lamps such as fluorescent or neon tube lamps, or in a newly-constructed internally lit sign that was originally designed for gas-discharge tube lamps, substantially without need for modifying the structure of the sign. The retrofitted or newly-constructed sign can thus be operated with lower energy and maintenance costs.
- These and other objects, advantages, purposes and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings.
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FIG. 1 is perspective view of a lighted sign assembly including a lamp support assembly in accordance with the present invention, and showing removal of a gas-discharge tube lamp; -
FIG. 2 is an end elevation of the lighted sign assembly ofFIG. 1 , and with the display sheet removed; -
FIG. 3 is a front elevation of the lighted sign assembly ofFIG. 1 , and with the display sheet removed; -
FIG. 4 is a perspective view of a lamp support assembly that is part of the lighted sign assembly ofFIG. 1 ; -
FIG. 5 is an end elevation of an elongate support member that is part of the lamp support assembly ofFIG. 4 ; -
FIG. 6 is a perspective view of the elongate support member ofFIG. 6 ; -
FIG. 7 is a perspective view of another lamp support assembly; -
FIG. 8 is an end elevation of an elongate support member that is part of the lamp support assembly ofFIG. 7 ; -
FIG. 9 is a perspective view of the elongate support member ofFIG. 7 ; -
FIG. 10 is a perspective view of the inboard side of an end cap that is part of the lamp support assemblies ofFIGS. 4 and 7 ; -
FIG. 11 is a perspective view of an outboard side of the end cap ofFIG. 10 ; -
FIG. 12 is a plan view of the inboard side of the end cap ofFIG. 10 ; -
FIG. 13 is a plan view of the outboard side of the end cap ofFIG. 10 ; -
FIG. 14 is a front elevation of the end cap ofFIG. 10 ; -
FIG. 15 is a sectional view of the end cap, taken along section line XV-XV ofFIG. 14 ; -
FIG. 16 is a sectional view of the end cap, taken along section line XVI-XVI ofFIG. 14 ; -
FIG. 17 is an end elevation of the end cap ofFIG. 10 ; -
FIG. 18 is a sectional view of the end cap, taken along section line XVIII-XVIII ofFIG. 17 ; -
FIG. 19 is a perspective view of the inboard side of another end cap, which is compatible for use with the lamp support assemblies ofFIGS. 4 and 7 ; -
FIG. 20 is a plan view of the outboard side of the end cap ofFIG. 19 ; -
FIGS. 21A and 21B are perspective views of the inboard side of the end cap ofFIG. 19 , withFIG. 21A showing cross sections of the elongate support members ofFIGS. 5 and 8 superimposed in phantom; -
FIG. 22 is a perspective view of a pair of conventional socket mounts for supporting and energizing a gas-discharge tube lamp; -
FIG. 23 is a perspective view of another pair of conventional socket mounts for supporting and energizing a gas-discharge tube lamp; and -
FIG. 24 is a plan view of a retrofit kit for use in converting a sign over from gas-discharge tube lamps to low-voltage lamp units. - Referring now to the drawings and the illustrative embodiments depicted therein, a
lamp support assembly 10 is provided for interior lighting of a sign 12 (FIG. 1 ), which may be a single or double-sided sign (or a sign having substantially any number of sides or surfaces) that is internally-lit or “back-lit”.Lamp support assembly 10 allows forsign 12, which may have been originally designed and manufactured for internal lighting by one or more gas-discharge lamps such as fluorescent orneon tube lamps 21 or the like, to be retrofitted with alternative lighting, such as low-voltage lighting, largely or substantially without modifications to the original sign. -
Lamp support assembly 10 includes anelongate support member 14 for supporting one or moreelectric lamp units 28 which, in the illustrated embodiment, each include four light emitting diode (LED) lamps 32 (FIGS. 1 and 3 ). Elongatesupport member 14 hasopposite end portions parallel frame members 22 ofsign 12. Eachopposite end portion elongate support member 14 is fitted with anend cap 16. Eachend cap 16 has an inwardly-facingside 16 a and an outwardly-facingside 16 b, such as shown inFIGS. 10-13 . Inwardly-facingsides 16 a are configured to engage one of theopposite end portions elongate support member 14, while outwardly-facingsides 16 b include amechanical coupling element 18 for engaging one of two standard electro-mechanical mounts orsockets fluorescent tube lamp 21, as will be described below. Optionally, purely-mechanical mounts orsockets sockets sockets mounts FIGS. 1 and 3 ),lamp support assembly 10 is releasably supportable by and between themounts FIGS. 4 , 7, 10, 11, 13-15, 17, and 18), which are provided on themounts - Sign 12 further includes a
display sheet 23 that may be a rigid, semi-rigid, or flexible sheet material, which is supported byframe members 22 or by coupling elements (e.g. clips or other mechanical fasteners) or adhesives or the like, that are associated with the sign. For example, such sheet materials may be made of cloth, paper, glass, polymeric material, or the like.Display sheet 23 is at least partially translucent so that at least some of the light emitted from inside of thesign 12 can pass through thesheet 23 and can be seen by persons located within view of the sign. Optionally, the translucent portions of thedisplay sheet 23 may be openings or apertures in the sheet. The display sheet may have substantially any lettering, symbols, artwork, coloring, indicia, or the like, which are made visible (or made more visible) when illuminated from behind (i.e., from inside of sign 12). -
Elongate support member 14 has an I-beam cross section with adouble web portion 24 andflange portions 26 on opposite ends of the web portion 24 (FIGS. 1-4 , 6, and 7).Web portion 24 comprises a pair of spacedplates flange portions 26, such as shown inFIGS. 5 and 6 .Elongate support member 14 is configured to support the plurality ofelectric lamp units 28 along one or both opposite sides of web portion 24 (FIGS. 1-3 ), such as for lighting a one-sided sign or a two-sided sign, respectively. - Optionally, and with reference to
FIGS. 7-9 , analternative support member 14′ includes aweb portion 24′ that is comprised of a single plate withopposite flange portions 26′.Flange portions 26′ include L-shapedflange tips 27′ that may enhance the structural rigidity ofsupport member 14′, and that may provide a retaining function for electric lamp units that are positioned along theweb portion 24′, particularly if the L-shapedflange tips 27′ along one side ofweb portion 24′ are spaced more closely together than the width ofelectric lamp units 28 so that the lamp units can generally only be slid longitudinally alongsupport member 14 until fixed in place, such as described below.Elongate support members - The inwardly-facing
sides 16 a ofend caps 16 include a plurality of wall-like projections 30 (FIGS. 1-4 , 7, 10-12, 14, 15, 17, and 18) for engaging the I-beam cross section of theelongate support member 14 at the opposite ends 14 a, 14 b thereof, such as shown inFIGS. 1-4 .Projections 30 include a pair of flange-engagingwalls 30 a on respective opposite ends ofend cap 16, and a pair of web-engagingwalls 30 b that span substantially across inwardly-facingside 16 a ofend cap 16, between flange-engagingwalls 30 a. A flange-receivinggap 31 a (FIGS. 12 and 14 ) is defined between each flange-engagingwall 30 a and the nearby ends of web-engagingwalls 30 b for receiving therespective flange portions elongate support members FIGS. 10 and 12 ) is defined between the pair of web-engagingwalls 30 b, for receiving the single-wall web portion 24′ ofsupport member 14′. Web-engagingwalls 30 b are spaced such that their outwardly-facing surfaces (i.e., opposite thegap 31 b) can frictionally engage the inner surfaces of the spacedplates wall web portion 24 ofelongate support member 14. Thus,projections 30 are arranged to frictionally engage respective web and flange portions of eithersupport member elongate support member -
Mechanical coupling element 18, which is disposed along outwardly-facingside 16 b of end cap 16 (FIGS. 4 , 7, 10, 11, 13-15, 17, and 18), substantially replicates the structure of the conventional electro-mechanical end coupler 21 a of a “high output”fluorescent tube lamp 21, and is shaped to engage or be received in the conventional or standard electro-mechanical sockets or mounts 20 a, 20 b. Standard electro-mechanical sockets or mounts 20 a, 20 b may be of the type commonly referred to as a “Kulka socket”, such as that shown and described in U.S. Pat. No. 5,122,074, the disclosure of which is hereby incorporated herein by reference, and such as may be available as Part Nos. 582GDF and/or 583GDF from Voltarc Technologies, Inc. of Waterbury, Conn. -
Mechanical coupling elements 18 include a base plate orflange 18 a and a male prong orprojection 18 b extending outwardly frombase plate 18 a (FIGS. 4 , 7, 10, 11, 13-15, 17, and 18).Male projection 18 b has a pair ofopposite side walls 44 that are spaced from each other and joined at their ends byrounded end walls 46 to define an interior cavity 48 (FIGS. 11 and 13 ). Inside ofcavity 48 is a pair of recessedshoulders 50 that project outwardly frombase plate 18 a, but not as far as doside walls 44, and which form the outward extent ofrounded end walls 46 so that agap 52 is formed between end portions of the opposite side walls 44 (FIGS. 11 , 13, 15, 17, and 18). Unlike the conventional electro-mechanical end couplers 21 a offluorescent tube lamp 21, however,mechanical coupling elements 18 lack electrical conductors since they need not be used to conduct electricity toelectric lamp units 28. In all other respects,mechanical coupling elements 18 may be structurally very similar or even identical to the conventional electro-mechanical end couplers 21 a of high outputfluorescent tube lamps 21, which are configured to mechanically and electrically engage the standard electro-mechanical sockets or mounts 20 a, 20 b of sign 12 (FIG. 1 ).Mechanical coupling elements 18 may be made from injection-molded non-metal material, for example, such as a resinous plastic material or the like. - Optionally, it is envisioned that low-voltage wiring for
lamp units 28 could be electrically coupled to electrical conductors mounted in thecoupling elements 18 of the end caps 16 (i.e., to makecoupling elements 18 substantially similar to theend couplers 21 a of fluorescent tube lamps 21). This would allow eachlamp support assembly 10 to be installed in the sign's original electro-mechanical mounts orsockets respective frame members 22 and electrically coupled to a power source in substantially the same manner as thefluorescent tube lamps 21, as long as the power supplied to electro-mechanical mounts high voltage wiring 60 fromballast 34 and high-voltage power source 62, and instead supplying low voltage power to wiring 60 with low-voltage power source 36. - Optionally, and with reference to
FIGS. 19-21B , analternative end cap 116 has an inwardly-facingside 116 a (FIGS. 19 , 21A, and 21B) including a plurality of wall-like projections elongate support members FIG. 21A . An outwardly-facingside 116 b ofend cap 116 includes a mechanical coupling element 118 (FIG. 20 ) that is substantially identical tocoupling element 18 ofend cap 16, as described above. Wall-like projections gaps 131 a and web-receivinggaps 131 b (FIGS. 19 and 21B ), which are substantially similar togaps walls end cap 16, as described above. However, web-engagingwalls 130 b are discontinuous or segmented to define a pattern of gaps 131 c along their respective lengths. - Gaps 131 c permit inwardly-facing
side 116 b ofend cap 116 to receive the dual-webelongate support member 14 in either of two orientations, such as shown inFIG. 21A , and/or to engage a dual-web elongate support member having shorter-length webs in which the flange portions would be received in gaps 131 c that are spaced inwardly from flange-engagingwalls 130 a and flange-receivinggap 131 a, while also remaining capable of receiving a single-web elongate support member such assupport member 14′, as shown. Thus,alternative end cap 116 can be mounted to different elongate support members in different orientations, which may facilitate directing light fromlamp units 28 laterally toward the perimeter ends or sides of the sign, rather than directly outwardly through thedisplay sheet 23, for example. - In the illustrated embodiment, electro-
mechanical mount 20 a is a fixed-position mount (such as Part No. 582GDF, available from Voltarc Technologies, Inc.) while electro-mechanical mount 20 b is a spring-loaded mount (such as Part No. 583GDF, available from Voltarc Technologies, Inc.), such as shown inFIGS. 1-3 and 22.Mounts socket portions 54 for receivingconventional end couplers 21 a of fluorescent tube lamps 21 (FIGS. 1-3 ), and respective mountingportions FIGS. 2 and 22 ) for engaging a frame portion, such asframe member 22. Mountingportion 56 b of spring-loadedmount 20 b includes a coil spring 58 (FIGS. 1-3 and 22) disposed around mountingportion 56 b and held in compression betweensocket portion 54 and frame member 22 (FIGS. 1-3 ). This allows spring-loadedmount 20 b to be somewhat extendable and retractable relative to framemember 22, while being biased outwardly fromframe member 22 byspring 58 to hold fluorescent tube lamp 21 (or lamp support assembly 10) in place. As noted above, the purely-mechanical mounts orsockets standard mounts mechanical mount 40 a and a spring-loadedmechanical mount 40 b, and may be provided as optional replacements for electro-mechanical mounts - Optionally, an alternative standard or conventional electro-mechanical stand-off mount 20′ (or a corresponding purely-mechanical mount, not shown) may be used (
FIG. 23 ), which stands off from a mounting surface such as a frame member for supporting a fluorescent tube lamp (or lamp support assembly 10) substantially parallel to the mounting surface. Standard stand-off mounts 20′ include a fixed-position stand-off mount 20 a′ (such as Part No. 530.2K, available from Voltarc Technologies, Inc.) and a spring-loaded stand-off mount 20 b′ (such as Part No. 530.1K, available from Voltarc Technologies, Inc.). Likemounts socket portion 54′ and a mounting portion orhousing 56′, with an internal spring (not shown) disposed in the housing of spring-loaded stand-off mount 20 b′ to bias itssocket portion 54′ outwardly, such as shown inFIG. 23 . - Optionally, various components of the
lamp support assemblies 10 can be provided in a retrofit kit 42 (FIG. 24 ). In the illustrated embodiment,retrofit kit 42 includes one or moreelongate extrusions 114 and a pair ofend caps 16 for eachelongate support member 14 that will be formed fromelongate extrusions 114. It will be appreciated that the term “elongate extrusion” is used for convenience, and thatelongate support members 14 may be formed via any desired method, such as molding or machining or extruding or the like. Optionally,retrofit kit 42 may include one or more mechanical replacement mounts orsockets kit 42 may also include one or moreelectric lamp units 28, low-voltage wiring 38, a low-voltage power source orconverter 36,mechanical fasteners 61, adhesives 63 (such as double-sidedadhesive pads 63 a or achemical adhesive 63 b), and/or the like. - Thus,
lamp support assembly 10 can be positioned between standard electro-mechanical mounts sockets mechanical coupling element 18 of theend cap 16 atend 14 b ofelongate support member 14 with the spring-loadedsocket spring 58 to push mounting portion 56 (or a corresponding mounting portion ofmechanical socket 40 b) further intoframe member 22, and then aligning the othermechanical coupling element 18 of the end cap at theopposite end 14 a ofelongate support member 14 with the fixedsocket assembly 10 so thatspring 58 forces themechanical coupling element 18 at theopposite end 14 a ofelongate support member 14 into engagement with the fixedsocket lamp support assembly 10 between therespective sockets voltage wiring 38 may be electrically coupled to low-voltage power source 36 either before or after installation oflamp support assembly 10. It will be appreciated thatlamp support assembly 10 can be removed simply by following the above steps in reverse order. - A method of retrofitting or assembling a sign to use alternative lamp units differs little from the procedure for installing and removing
lamp support assembly 10, described above, although various optional steps may be added, as will now be described.Lamp support assembly 10 may be fabricated by cuttingelongate support member elongate support member electric lamp units 28 along one or both sides ofweb portion elongate support member Electrical lamp units 28 are typically installed along one or both sides ofweb portion elongate support member FIGS. 1 and 3 ), adhesives, or the like, prior to installation of thelamp support assembly 10 at thesign 12, althoughlamp units 28 can be added later, if desired. In the case ofelongate support member 14′ havingflange portions 26′ with L-shapedflange tips 27′, thelamp units 28 may be inserted between L-shapedflange tips 27′ andweb portion 24′ from either end of theelongate support member 14′, such as in stacked or spaced arrangement, and held in place by L-shapedflange tips 27′ and/ormechanical fasteners 61, adhesives, or the like. Low-voltage wiring 38 may be pre-installed atlamp units 28, or may be installed atlamp units 28 after they are attached to elongatesupport member elongate support member - If the installation is a retrofit,
fluorescent tube lamps 21 can be removed from sign 12 (FIG. 1 ) following the removal steps described above for lamp support assembly 10 (i.e. following the installation steps in reverse order), andlamp support assemblies 10 can then be installed between respective pairs of standard electro-mechanical mounting sockets mechanical mounting sockets mechanical replacement sockets fluorescent tube lamps 21 are removed. Otherwise, if the installation is in a new sign, the installer may choose whether to use standard electro-mechanical mounting sockets mechanical mounting sockets frame members 22. - Once
lamp support assemblies 10 are installed, the low-voltageelectrical wiring 38 is routed to a low-voltage electrical power source 36 (FIG. 1 ) so that theelectric lamp units 28 can be supplied with the appropriate electrical power. Optionally, as in the case of a retrofit of a sign that had been previously set up or designed forfluorescent tube lamps 21, the installer may choose to cut, remove, or disable any high-voltage wiring 60 (FIG. 1 ) associated with thetube lamps 21 andballast 34 and high-voltage power source 62. The installer may also choose to remove or disable theballast 34, and may electrically couple low-voltage power source 36 to highvoltage power source 62 via high-voltage wiring 64, which may be routed in an approved method, either externally to sign 12 or through frame members 22 (which may be hollow extruded sections, as shown inFIGS. 1 and 2 ). Depending on local or national electrical codes, it may be permissible to route low-voltage wiring 38 outside of conduits or frame members, which can simplify the installation process. - Therefore, the present invention provides a lighting mount assembly and method that facilitates the retrofitting of existing interior-lit signs, which may have been originally manufactured for supporting and energizing high-output gas-discharge lamps, such as fluorescent or neon tube lamps or the like. The signs may be retrofitted with alternative lamps such as low-voltage LED lamps or the like, although it will be appreciated that principles of the present invention can be practiced in connection with substantially any type of lighting as an alternative to gas-discharge lamps such as fluorescent tube lamps. The lighting mount assembly can also be used in the production of new interior-lit signs that are equipped for low-voltage lighting, substantially without modifying the mechanical or structural features of the signs, which may have originally been designed to be internally lit by one or more fluorescent tube lamps or the like.
- Changes and modifications in the specifically described embodiments can be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law including the doctrine of equivalents.
Claims (21)
Priority Applications (2)
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US13/302,235 US9311835B2 (en) | 2010-11-24 | 2011-11-22 | Lighting mount for interior-lighted signage and method of retrofitting a lighted sign |
CA2759366A CA2759366C (en) | 2010-11-24 | 2011-11-23 | Lighting mount for interior-lighted signage and method of retrofitting a lighted sign |
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US41715610P | 2010-11-24 | 2010-11-24 | |
US13/302,235 US9311835B2 (en) | 2010-11-24 | 2011-11-22 | Lighting mount for interior-lighted signage and method of retrofitting a lighted sign |
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US20120124874A1 true US20120124874A1 (en) | 2012-05-24 |
US9311835B2 US9311835B2 (en) | 2016-04-12 |
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US13/302,235 Active 2034-10-15 US9311835B2 (en) | 2010-11-24 | 2011-11-22 | Lighting mount for interior-lighted signage and method of retrofitting a lighted sign |
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US11867364B2 (en) | 2018-05-01 | 2024-01-09 | Keystone Technologies, LLC | LED light tubes, light boxes including LED light tubes and methods for installation of LED light tubes in light boxes |
US11002438B2 (en) | 2019-04-03 | 2021-05-11 | Sidney Howard Norton | Adjustable clip-on base for LED assembly |
US11339933B2 (en) * | 2019-11-06 | 2022-05-24 | Open Platform Systems Llc | Universal LED fixture mount kit |
WO2021207784A1 (en) * | 2020-04-15 | 2021-10-21 | Sinext Pty Ltd | Signage assembly |
US11199317B1 (en) | 2020-08-14 | 2021-12-14 | Scott Fetzer SFEG | Light stick bus system |
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US9311835B2 (en) | 2016-04-12 |
CA2759366C (en) | 2017-01-24 |
CA2759366A1 (en) | 2012-05-24 |
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